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The Test Stand 1C at the Air Force Astronautic Laboratory (AFAL), Edwards AFB, Calif., was originally designed for F-1 liquid propellant engines. The stand was modified to handle a five and one half segment Solid Rocket Motor (SRM) Titan 34D vertical static firing test. The main design drivers and analysis effort utilized in the modification of the test stand are discussed.
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This report is based on the early design concepts for a communications network for the Advanced Solid Rocket Motor (ASRM) facility being built at Yellow Creek near Iuka, MS. The investigators have participated in the early design concepts and in the evaluation of the initial concepts. The continuing system design effort and any modification of the plan will require a careful evaluation of the required bandwidth of the network, the capabilities of the protocol, and the requirements of the controllers and computers on the network. The overall network, which is heterogeneous in protocol and bandwidth, is being modeled, analyzed, simulated, and tested to obtain some degree of confidence in its performance capabilities and in its performance under nominal and heavy loads. The results of the proposed work should have an impact on the design and operation of the ASRM facility.
New, more-efficient designs for aircraft jet engines are not capable of supplying the large quantities of bleed air necessary to provide pressurization and air conditioning for the environmental control systems (ECS) of the next generation of large passenger aircraft. System analysis and engineering have determined that electrically-driven ECS can help to maintain the improved fuel efficiencies; and electronic controllers and induction motors are now being developed in a NASA/NPD SBIR Program to drive both types of ECS compressors. Previous variable-speed induction motor/controller system developments and publications have primarily focused on field-oriented control, with large transient reserve power, for maximum acceleration and optimum response in actuator and robotics systems. The application area addressed herein is characterized by slowly-changing inputs and outputs, small reserve power capability for acceleration, and optimization for maximum efficiency. This paper therefore focuses on the differences between this case and the optimum response case, and shows the development of this new motor/controller approach. It starts with the creation of a new set of controller requirements. In response to those requirements, new control algorithms are being developed and implemented in an embedded computer, which is integrated into the motor controller closed loop. Buffered logic outputs are used to drive the power switches in a resonant-technology, power processor/motor-controller, at switching/resonant frequencies high enough to support efficient high-frequency induction motor operation at speeds up to 50,000-RPA
The concept, design, and features are described of a lightweight, high strength, modular robot manipulator being developed for space and commercial applications. The manipulator has seven fully active degrees of freedom and is fully operational in 1 G. Each of the seven joints incorporates a unique drivetrain design which provides zero backlash operation, is insensitive to wear, and is single fault tolerant to motor or servo amplifier failure. Feedback sensors provide position, velocity, torque, and motor winding temperature information at each joint. This sensing system is also designed to be single fault tolerant. The manipulator consists of five modules (not including gripper). These modules join via simple quick-disconnect couplings and self-mating connectors which allow rapid assembly and/or disassembly for reconfiguration, transport, or servicing. The manipulator is a completely enclosed assembly, with no exposed components or wires. Although the initial prototype will not be space qualified, the design is well suited to meeting space requirements. The control system provides dexterous motion by controlling the endpoint location and arm pose simultaneously. Potential applications are discussed.
The NASA Revolutionary Vertical Lift Technology Project has created several Urban Air Mobility reference design vehicles to aid the burgeoning UAM industry. With over 700 conceptual designs already proposed, much interest has been generated across many unique configurations to bring vertical flight to the masses. The quadrotor configuration is one of the NASA reference vehicles, and does have some conceptual designs proposed in the industry. This study looks at the conceptual design of a coaxial quadrotor vehicle as an extension of the NASA RVLT quadrotor concept vehicle. The coaxial quadrotor has a similar layout to the quadrotor, but with a coaxial rotor at each of the four corners of the vehicle. Trade studies carried out using the NASA Design and Analysis of Rotorcraft (NDARC) tool analyzed the vehicle sizing, design gross weight, and performance for four design variants. The variants all use the baseline coaxial quadrotor layout, but analyze the effects of two major design choices: 1) variable pitch vs variable speed rotor control, and 2) motor to rotor power transmission via a gearbox vs direct-drive. The results indicate one design variant may have more benefits on some of the design objectives while another configuration may better satisfy the others.
Many contemporary Advanced Air Mobility (AAM), and more specifically, urban air mobility (UAM) vehicle designers are attracted to variable rotor speed-controlled designs with multiple rotors because of the great potential for mass savings compared to more traditional, variable blade pitch-controlled vehicles. These designs are based on the assumption that the stability and control of recreation or basic utility-sized drones can be scaled to larger passenger-sized vehicles. Previous work had shown the challenges in stabilizing passenger-sized quadcopters. In this study, power constraints were made less restrictive and varied, allowing more control power. Motor parameters such as efficiency, nominal voltage and current operating point, and rise time of the rotor speed controller step response were studied. By fixing the efficiency of the motor to 95% and assuming a motor voltage to current ratio of 2.0 (previously, assumed to be 1.0), the authors were able to stabilize the quadcopter in the roll axis because this allowed the vehicle to achieve adequate rise times between 0.4 and 0.8 s. This motor optimization was extended to a hexacopter and octocopter designed to the same payload size and mission as the quadcopter. The three vehicle configurations and their motor speed controllers were compared. It was found that while hexacopter and octocopter required more mass and overall power; all three configurations had similar margins required for control. However, the hexacopter and octocopter were able to use this power margin to achieve lower rise times (i.e. the vehicle responded more quickly to pilot inputs) than the quadcopter, with the octocopter having the lowest rotor response rise time of the three vehicle configurations studied.
Subscale test motors are often used for the evaluation of solid rocket motor component materials such as internal insulation. These motors are useful for characterizing insulation performance behavior, screening insulation material candidates and obtaining material thermal and ablative property design data. One of the primary challenges associated with using subscale motors however, is the uncertainty involved when extrapolating the results to full-scale motor conditions. These uncertainties are related to differences in such phenomena as turbulent flow behavior and boundary layer development, propellant particle interactions with the wall, insulation off-gas mixing and thermochemical reactions with the bulk flow, radiation levels, material response to the local environment, and other anomalous flow conditions. In addition to the need for better understanding of physical mechanisms, there is also a need to better understand how to best simulate these phenomena using numerical modeling approaches such as computational fluid dynamics (CFD). To better understand and model interactions between major phenomena in a subscale test motor, a numerical study of the internal flow environment of a representative motor was performed. Simulation of the environment included not only gas dynamics, but two-phase flow modeling of entrained alumina particles like those found in an aluminized propellant, and offgassing from wall surfaces similar to an ablating insulation material. This work represents a starting point for establishing the internal environment of a subscale test motor using comprehensive modeling techniques, and lays the groundwork for improving the understanding of the applicability of subscale test data to full-scale motors. It was found that grid resolution, and inclusion of phenomena in addition to gas dynamics, such as two-phase and multi-component gas composition are all important factors that can effect the overall flow field predictions.
A frequency-domain design methodology is applied to a DC motor-speed control system and the results are compared to those obtained using l1-optimal control theory (Pearson and Bamieh, 1990). Both methods synthesize controllers that maximize the allowable size of an unknown-but-bounded disturbance while satisfying prespecified constraints on the control, the control rate, and the outputs. The frequency-domain design technique in general results in much lower-order compensators than those required by the l1-optimal method for a given size of disturbance. Also, the design trade-offs regarding the bandwidth of the system, the size of the disturbance input, and the structural complexity of the controller transfer function become quite transparent.
Static and dynamic combustion phenomena effects on grain structural design for solid propellant rocket engine
Electroforming methods in design and fabrication of liquid propellant rocket motor injectors and composite thrust chambers
The primary objectives were to develop a Base Heating Indicator Code and a new plume radiation code for the Space Shuttle. Additional work included: revision of the Space Shuttle plume radiation environment for changes in configuration and correction of errors, evaluation of radiation measurements to establish a plume radiation model for the SRB High Performance Motor (HPM) plume, radiation predictions for preliminary designs, and participation in hydrogen disposal analysis and testing for the VAFB Shuttle launch site. The two most significant accomplishments were the development of the Base Heating Indicator Code and the Shuttle Engine Plume Radiation (SEPRAD) Code. The major efforts in revising the current Shuttle plume radiation environment were for the Orbiter base heat shield and the ET components in the Orbiter-ET interface region. The work performed is summarized in the technical discussion section with references to the documents containing detailed results. The technical discussion is followed by a summary of conclusions and recommendations for future work.
A new Relatchable Launch Mechanism was developed which enables a deployable system to be restrained and released repeatedly rather than the normal one shot release systems of the past. The deployable systems are of the self extending type which rely on a lanyard attached to a drive motor to control the deployment and retraction. The Relatch Mechanism uses the existing drive motor to also actuate the latch. The design and kinematics of the Relatch Mechanism as used on two flight programs are described.
Current status of a steady state, axisymmetric analysis of an experimental 11 inch diameter hybrid rocket motor internal flow field is given. The objective of this effort is to develop a steady state axisymmetric model of the 11 inch hybrid rocket motor which can be used as a design and/or analytical tool. A test hardware description, modeling approach, and future plans are given. The analysis was performed with FDNS implementing several finite rate chemistry sets. A converged solution for a two equation and five species set on a 'fine' grid is shown.
Linear proof-mass actuator (LPMA) is friction-driven linear mass actuator capable of applying controlled force to structure in outer space to damp out oscillations. Capable of high accelerations and provides smooth, bidirectional travel of mass. Design eliminates gears and belts. LPMA strong enough to be used terrestrially where linear actuators needed to excite or damp out oscillations. High flexibility designed into LPMA by varying size of motors, mass, and length of stroke, and by modifying control software.
An eddy current system and method enables detection of sub-surface damage in a cylindrical object. The invention incorporates a dual frequency, orthogonally wound eddy current probe mounted on a stepper motor-controlled scanning system. The system is designed to inspect for outer surface damage from the interior of the cylindrical object.
Creare Incorporated and NASA Goddard Space Flight Center developed and space qualified two wide range pumps (WRPs) that were included in the Sample Analysis at Mars (SAM) instrument. This instrument was subsequently integrated into the Mars Science Laboratory (MSL) "Curiosity Rover," launched aboard an Atlas V rocket in 2011, and landed on August 6, 2012, in the Gale Crater on Mars. The pumps have now operated for more than 18 months in the Gale Crater and have been evacuating the key components of the SAM instrument: a quadrupole mass spectrometer, a tunable laser spectrometer, and six gas chromatograph columns. In this paper, we describe the main design challenges and the ways in which they were solved. This includes the custom design of a miniaturized, high-speed motor to drive the turbo drag pump rotor, analysis of rotor dynamics for super critical operation, and bearing/lubricant design/selection.
Hybrid turboelectric aircraft-with gas turbines driving electric generators connected to electric propulsion motors-have the potential to transform aircraft design. Decoupling power generation from propulsion enables innovative aircraft designs, such as blended-wing bodies, with distributed propulsion. These hybrid turboelectric aircraft have the potential to significantly reduce emissions, decrease fuel burn, and reduce noise, all of which are required to make air transportation growth projections sustainable. The power density requirements for these electric machines can only be achieved with superconductors, which in turn require lightweight, high-capacity cryocoolers.